Barrier operator strain detection

Abstract

A barrier sensor device and associated control device monitor operation of a barrier operator system. The barrier sensor device monitors operation of barrier operators for undesirable amounts of strain without barrier operator force as an input. The barrier sensor device instead detects both motion and tilt of a barrier. By monitoring these two aspects of barrier operation, the barrier sensor device compiles data that can be analyzed by the control device and compared to un-strained or previously compiled barrier operator data to determine whether the barrier operator system is under strain and requires service.

What is claimed is: 
     
       1. A retrofit monitoring apparatus for a movable barrier system, the apparatus comprising:
 one or more sensing devices configured to be secured to a movable barrier driven by a movable barrier operator and to obtain position and movement data of the movable barrier, the position and movement data comprising data regarding a movable barrier operation comprising an open time and a close time, the sensing devices being configured to determine the open time for the movable barrier to travel from a closed position to an open position and determine the close time for the movable barrier to travel from an open position to a closed position, wherein the sensing devices determine the open time and the close time without communication with the movable barrier operator; 
 a control device remote from the movable barrier operator and configured to be in communication with the sensing devices, the control device configured to:
 receive the position and movement data; 
 calculate a ratio of the open time to the close time; 
 determine a stress value from the ratio; 
 compare the stress value to target operational data; and 
 selectively generate a service signal in response to comparing the stress value to the target operational data. 
 
 
     
     
       2. The apparatus of  claim 1  wherein the control device is further configured to generate the service signal to indicate a potential problem with the status of at least one of: a movable barrier operator; a counter-balance mechanism; or movable barrier guidance structure. 
     
     
       3. The apparatus of  claim 1  wherein the sensing devices comprise a tilt switch and accelerometer configured to determine position and movement of the movable barrier. 
     
     
       4. The apparatus of  claim 1  wherein the control device is configured to send the service signal in response to the stress value exceeding the target operational data by a factor of 2 or more. 
     
     
       5. The apparatus of  claim 1  wherein the control device is further configured to account for factors affecting the movable barrier operation in determining the stress value, the factors comprising one or more of friction, gravity, movable barrier size, weather, temperature, or a number of previous operations. 
     
     
       6. The apparatus of  claim 1  wherein the target operational data comprises an acceptable range for the stress value; and the control device is configured to:
 receive data regarding a series of movable barrier operations; 
 compare stress values from the data of the series of movable barrier operations to the acceptable range for the stress value; and 
 generate the service signal in response to determining that a preset number of the stress values exceed the acceptable range. 
 
     
     
       7. The apparatus of  claim 1  wherein the control device is configured to:
 receive data regarding a series of movable barrier operations; 
 calculate a rolling average of the stress values of the data of the series of movable barrier operations; 
 calculate deviations of the stress values from the rolling average; and 
 compare the deviations of the stress values to the target operational data. 
 
     
     
       8. The apparatus of  claim 7  wherein the target operational data comprises the rolling average; and the control device is configured to generate the service signal in response to determining that a preset number of the deviations of the stress values exceed a preset percentage over the rolling average. 
     
     
       9. The apparatus of  claim 7  wherein the target operational data comprises a benchmark rolling average of stress values compiled after installation or reset of the movable barrier operator. 
     
     
       10. The apparatus of  claim 9  wherein the control device is configured to:
 utilize a first in, first out (FIFO) process to sequentially update the rolling average of the stress values to create updated deviations of the stress values from the rolling average; and 
 compare the updated deviations to the benchmark rolling average. 
 
     
     
       11. The apparatus of  claim 1  further comprising a processing device operably coupled to the sensing devices; and
 wherein the sensing devices and the control device are remote from one another; and the sensing devices are configured to obtain and the processing device is configured to cause the position and movement data to be transmitted according to one or more parameters, the parameters being configurable by a configuration signal sent to the processing device from the control device. 
 
     
     
       12. The apparatus of  claim 11  wherein the control device is configured to transmit the configuration signal in response to reception of a signal from the processing device. 
     
     
       13. The apparatus of  claim 11  wherein the sensing devices are configured to operate in a sleep mode subject to a timer on the processing device, the processing device configured to obtain and transmit the position and movement data in response to expiration of the timer. 
     
     
       14. A retrofit monitoring apparatus for a movable barrier system, the apparatus comprising:
 a housing configured to be secured to a movable barrier driven by a movable barrier operator; 
 one or more sensing devices disposed within the housing and configured to obtain position and movement data of the movable barrier, the position and movement data comprising data regarding a movable barrier operation comprising an open time and a close time; and 
 wherein the sensing devices are configured to be in communication with a control device remote from the movable barrier operator, the control device configured to:
 receive the position and movement data; 
 calculate a ratio of the open time to the close time; 
 determine a stress value from the ratio; 
 compare the stress value to target operational data; and 
 selectively generate a service signal in response to comparing the stress value to the target operational data. 
 
 
     
     
       15. The apparatus of  claim 14  wherein the control device is disposed within the housing. 
     
     
       16. The apparatus of  claim 14  further comprising a processing device disposed within the housing and operably coupled to the sensing devices; and
 wherein the sensing devices and the control device are remote from one another; and the sensing devices are configured to obtain and the processing device is configured to cause the position and movement data to be transmitted to the control device according to one or more parameters, the parameters being configurable by a configuration signal sent to the processing device from the control device. 
 
     
     
       17. The apparatus of  claim 16  wherein the control device is configured to transmit the configuration signal in response to reception of a signal from the processing device. 
     
     
       18. The apparatus of  claim 16  wherein the sensing devices are configured to operate in a sleep mode subject to a timer on the processing device, the processing device configured to obtain and transmit the position and movement data in response to expiration of the timer. 
     
     
       19. The apparatus of  claim 14  wherein the control device is further configured to generate the service signal to indicate a potential problem with the status of at least one of: a movable barrier operator; a counter-balance mechanism;
 or movable barrier guidance structure. 
 
     
     
       20. The apparatus of  claim 14  wherein the sensing devices comprise a tilt sensor configured to determine position of the movable barrier and an accelerometer sensor configured to determine movement of the movable barrier. 
     
     
       21. The apparatus of  claim 18 , the sensing devices being configured to:
 determine the open time for the movable barrier to travel from a closed position to an open position by monitoring a status of the tilt sensor and how long the accelerometer sensor senses movement; and 
 determine the close time for the movable barrier to travel from an open position to a closed position by monitoring a status of the tilt sensor and how long the accelerometer sensor senses movement; 
 wherein the sensing devices determine the open time and the close time without communication with the movable barrier operator. 
 
     
     
       22. The apparatus of  claim 14  wherein the control device is configured to generate the service signal in response to the stress value exceeding the target operational data by a factor of 2 or more. 
     
     
       23. The apparatus of  claim 14  wherein the control device is further configured to account for factors affecting the movable barrier operation in determining the stress value, the factors comprising one or more of movable barrier size, weather, temperature, or a number of previous operations. 
     
     
       24. The apparatus of  claim 14  wherein the target operational data comprises an acceptable range for the stress value; and the control device is configured to:
 receive data regarding a series of movable barrier operations; 
 compare stress values from the data of the series of movable barrier operations to the acceptable range for the stress value; and 
 generate the service signal in response to determining that a preset number of the stress values exceed the acceptable range. 
 
     
     
       25. The apparatus of  claim 14  wherein the control device is configured to:
 receive data regarding a series of movable barrier operations; 
 calculate a rolling average of the stress values of the data of the series of movable barrier operations; 
 calculate deviations of the stress values from the rolling average; and 
 compare the deviations of the stress values to the target operational data. 
 
     
     
       26. The apparatus of  claim 25  wherein the target operational data comprises the rolling average; and the control device is configured to generate the service signal in response to determining that a preset number of the deviations of the stress values exceed a preset percentage over the rolling average. 
     
     
       27. The apparatus of  claim 25  wherein the target operational data comprises a benchmark rolling average of stress values compiled after installation or reset of the movable barrier operator. 
     
     
       28. The apparatus of  claim 27  wherein the control device is configured to:
 utilize a first in, first out (FIFO) process to sequentially update the rolling average of the stress values to create updated deviations of the stress values from the rolling average; and 
 compare the updated deviations to the benchmark rolling average. 
 
     
     
       29. A method comprising:
 obtaining position and movement data of a movable barrier driven by a movable barrier with one or more sensing devices secured to the movable barrier, the position and movement data comprising data regarding a movable barrier operation comprising an open time and a close time; 
 receiving the position and movement data at a control device remote from the movable barrier operator; 
 calculating, with the control device, a ratio of the open time to the close time; 
 determining, with the control device, a stress value from the ratio; and 
 comparing the stress value with the control device to target operational data; and 
 selectively generating a service signal with the control device in response to comparing the position and movement data to the target operational data. 
 
     
     
       30. The method of  claim 29  wherein generating the service signal comprises generating a service signal to indicate a potential problem with the status of at least one of: a movable barrier operator; a counter-balance mechanism; or movable barrier guidance structure. 
     
     
       31. The method of  claim 29  wherein obtaining the position and movement data comprises obtaining position and movement data with a tilt switch and accelerometer. 
     
     
       32. The method of any of  claim 31  wherein obtaining the position and movement data comprises obtaining, with the sensing device, data regarding the movable barrier operation comprising the open time and the close time without communication with the movable barrier operator, the obtaining the data regarding the movable barrier operation comprising:
 determining the open time for the movable barrier to travel from a closed position to an open position by monitoring a status of the tilt sensor and how long the accelerometer sensor senses movement; and 
 determining the close time for the movable barrier to travel from an open position to a closed position by monitoring a status of the tilt sensor and how long the accelerometer sensor senses movement. 
 
     
     
       33. The method of  claim 29  wherein generating the service signal comprises generating a service signal in response to the stress value exceeding the target operational data by a factor of 2 or more. 
     
     
       34. The method of  claim 29  further comprising accounting for factors affecting the movable barrier operation in determining the stress value with the control device, the factors comprising one or more of movable barrier size, weather, temperature, or a number of previous operations. 
     
     
       35. The method of  claim 29  wherein:
 receiving the position and movement data comprises receiving data regarding a series of movable barrier operations; and further comprising: 
 comparing the position and movement data to the target operational data comprises comparing stress values from the data of the series of movable barrier operations to an acceptable range for the stress value; and 
 generating the service signal comprises generating a service signal in response to determining that a preset number of the stress values exceed the acceptable range. 
 
     
     
       36. The method of  claim 29  wherein receiving the position and movement data comprises receiving data regarding a series of movable barrier operations; and further comprising: calculating a rolling average of the stress values of the data of the series of movable barrier operations; and calculating deviations of the stress values from the rolling average; and wherein comparing the position and movement data to the target operational data comprises comparing the deviations of the stress values to the target operational data. 
     
     
       37. The method of  claim 36  wherein the target operational data comprises the rolling average; and generating the service signal comprises generating a service signal in response to determining that a preset number of the deviations of the stress values exceed a preset percentage over the rolling average. 
     
     
       38. The method of  claim 36  wherein comparing the deviations of the stress values to the target operational data comprises comparing the deviations of the stress values to a benchmark rolling average of stress values compiled after installation or reset of the movable barrier operator. 
     
     
       39. The method of  claim 38  further comprising utilizing a first in, first out (FIFO) process, with the control device, to sequentially update the rolling average of the stress values to create updated deviations of the stress values from the rolling average; and
 wherein comparing the deviations of the stress values to the benchmark rolling average comprises comparing the updated deviations of the stress values to the benchmark rolling average. 
 
     
     
       40. The method of  claim 29  wherein the sensing devices and the control device are remote from one another; and further comprising transmitting the position and movement data, with a processing device operably coupled to the sensing devices, to the control device according to one or more parameters, the parameters being configurable by a configuration signal sent to the processing device from the control device. 
     
     
       41. The method of  claim 40  further comprising transmitting the configuration signal at the direction of the control device in response to reception of a signal at the control device from the processing device. 
     
     
       42. The method of  claim 40  further comprising the sensing devices operating in a sleep mode subject to a timer on the processing device, and wherein transmitting the position and movement data comprises transmitting the position and movement data, with the processing device, in response to expiration of the timer.